< Frame assembly >
I started from frames. They were laser-cut from 9mm steel plates. I employed such thick plates so as to omit hornblock. Both frames are bolted together and the pedestals (horn slots) are trued up by end mill and oil stone.
Screw holes for horn stays are opened here.
After drilling necessary holes, the frames are separated.
The stretchers are also prepared by laser-cut. Only the both edges (bolting faces) are finished by end mill.
Only one screw hole in each side is opened first. Other holes are opened through the frames as follows.
1) Assemble the stretchers between the frames with one bolt in each side.
2) Drill counter-sunk through the frames.
3) Remove the stretchers. Drill and tap other holes following the counter-sunk.
Buffer beams will be fitted with steel angles. The steel angles should be trued up before use.
The buffer beams are assembled as follows.
1) Inner angles are bolted behind the buffer beam in a desired distance.
2) The buffer beam is set into the frames, clamped and drilled through the frames.
3) Inner and outer angles are put together and drilled through.
4) All parts are assembled and outer angles are drilled through the buffer beams.
The photo shows a leaf spring shaft guide made from a brass rectangle bar. Same as the stretchers, one screw hole is opened first, and another hole is copyed from the frames. Also the horn stays are prepared here. They are made from steel flat bar.
The frame assembly was finished. The whole length is 780mm, almost the same as the William. But its width is two times wider than the William.